Prefabricated Electrical Module and System

ABSTRACT

A prefabricated electrical module and system along with fabrication and installation methods are provided. The prefab electrical module includes a circuit breaker panel casing that houses multiple circuit breakers, and a chase extending upwardly from the panel casing that stows coiled lengths of homerun wiring attached to the circuit breakers. During transport, a temporary panel casing front cover protects the panel casing front, and a forwardly protruding guard cover with an upwardly projecting hoisting handle shields the front and top of the chase and wiring. During installation, a hoisting bracket is attached at the top of the stud bay into which the prefab electrical module will be installed. A drill-powered winch is then used to lift the module to the proper height in the bay. The panel casing, chase, wiring, and breakers remain in the wall. The hoisting bracket, temporary panel casing front cover, guard cover, drill, and winch are reusable.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of currently pending U.S.application Ser. No. 17/882,558 issuing as U.S. Pat. No. 11,769,994 onSep. 26, 2023, which claims priority to U.S. Provisional Application No.63/338,366 filed on May 4, 2022 and which is a continuation-in-part ofcurrently pending U.S. application Ser. No. 17/499,647 filed on Oct. 12,2021; U.S. application Ser. No. 17/499,647 claims priority to U.S.Provisional Application No. 63/090,699 and is a continuation-in-part ofUS Application Nos. 29/727,382, 29/727,367, 29/727,373, and 29/727,329that were filed on Mar. 10, 2020; the entire contents of the aforesaidapplications being incorporated herein by reference.

FIELD OF INVENTION

This invention relates generally to distribution of electric power, and,more particularly, to modules, frameworks, casings, and parts thereoffor use in an electrical construction system along with fabrication andinstallation techniques and methods thereof.

BACKGROUND OF THE INVENTION

Construction of any new building takes considerable time and manpower,but construction of multi-unit buildings and complexes presentssignificant additional logistical challenges, which lead to increasedcosts. Many workers are needed, and some types of work must be completedbefore other types of work can be started. Thus, the correct materialsand the proper workers must be in the right place, at the right time,and in the right order.

Typically, basic materials are transported to the construction site andassembled onsite by workers. One major bottleneck is the installation ofthe electrical system in the unit under construction, which isespecially a factor in multi-unit buildings. With traditionalconstruction methods electricians cannot begin the electrical roughinstallation process until the building is “dried-in,” which means thatframing and the installation of all windows, doors, and roofing iscomplete to create a weatherproof building envelope. Inspectors requirethe building to be dried-in prior to installation of electrical systemsto ensure no moisture begins to deteriorate non-waterproofed materials.If there are several floors in residential or commercial developments,quite a significant amount of time is spent waiting before theelectrical installation can even begin on the first floor. Thus,multi-unit construction is particularly expensive due to labor costs,time delays due to logistical issues, and slow or delayed roughinspection processes.

Other problems in electrical installations in new construction are dueto construction site issues such as material wastage or loss, qualitycontrol, and installation inconsistencies caused by differinginstallation procedures used by the various onsite electricians.

Accordingly, there is a need for an electrical construction system andmethods that minimize labor costs in the field, reduce time delays,increase consistent high-quality installations, and reduce the timeuntil the rough electrical installation is finished so that the roughelectrical inspection can be accomplished, because the cost savings canbe quite significant.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a prefabricated (“prefab”)electrical module that is weatherized for installation into a stud bayopening in a wall during construction of a building, and that isparticularly suited for easy and early installation into multiple unitsof a multi-unit building before building dry-in has been achieved. Inthe multi-unit building use case, for each unit, the prefab electricalmodule carrying the homerun wiring for the unit is installed early(before dry-in). The electrical modules for the lower floors can beinstalled before the upper floors are completed; this allows wiring ofthe units of a lower floor to occur weeks or months ahead of thetraditional schedule controlled by the dry-in date. The presentinvention is also directed to systems and methods for fabrication,shipping, and installation of the prefab electrical module.

The prefab electrical module comprises a lower compartment and an uppercompartment. The lower compartment houses the circuit breaker panelcasing with installed breakers to which the unit's homerun wiring isconnected. The chase forms the rear portion of the upper compartment,and the guard cover forms the front portion of the upper compartment.The upper compartment houses the homerun wiring that is pre-cut to therequired length, and which is stored in, and carried by, the electricalmodule. (A homerun length of wiring is the length of wiring needed toreach from the breaker to the first outlet or switch includingsufficient length to run the wiring and to accomplish the connection.)

The circuit breaker panel casing includes a top wall, bottom wall, sidewalls, and back that together define a lower compartment space of theelectrical module, which, for the main electrical panel for the unit,houses multiple breakers. Though the circuit breaker panel casing istypically metal, it may optionally be formed of other materials, such asplastic, or may be formed of a combination of materials, such as plasticand metal. Although the electrical module of the invention is describedin terms of a circuit breaker panel casing with breakers connectedwithin it, the module may alternatively enclose a low-voltage assemblyor other electrical component assembly. Therefore, the inventiveelectrical module may be used for any electrical component assembly fora residential or commercial installation and is not limited to the mainelectrical service panel described herein.

The chase extends upwardly from the circuit breaker panel casing todefine the rearmost portion of an upper compartment space. A guard coverfits over and extends outwardly from the front of the chase to form theforward portion (top, front sides, and front) of the upper compartmentspace. Therefore, together the chase and guard cover define the uppercompartment space. The upper compartment space is used for holding theunit's homerun wiring during transport to the jobsite and at the jobsiteuntil the wiring is run to the nearest switches and/or outlets in theunit. Strands of wiring, which have been cut to designated homerunlengths are secured onto the back of the chase but project outwardlybeyond the frontmost portion of the chase. The front of the chase andthe wiring protruding beyond the frontmost portion of the chase iscovered by and protected by the removable guard cover during shippingand after installation of the module within a stud bay, until it is nolonger needed after the module's wiring is run to the homerun switchesand outlets.

The prefab electrical module and system include permanent componentsthat remain within the stud bay after completion of the unit and includecomponents that are used in transport and/or installation of the modulebut that then can be reused during transport and/or installation ofother prefab electrical modules. The permanent components include theunit's homerun wiring, a circuit breaker panel casing that housesmultiple breakers, and a chase attached to and extending above the panelcasing. The reusable components of the module include a temporary panelcasing front cover for the circuit breaker panel casing and a guardcover for shielding the front and top of the chase (and its carriedwiring) during transport and installation. Other parts of the system arealso reusable. Shipping pallets that have carried the modules to thejobsite can be reused. During module installation, a hoisting bracket isattached at the top of a stud bay. A drill-powered winch and a handhelddrill are used with the hoisting bracket to lift the module into thebay. These are reusable for the installation of multiple modules.

When the electrician at the fabrication facility connects the wiring tothe breakers within the panel casing, predetermined electrical layoutplans are followed. The breaker and/or wire is labeled.

In aspects, the wiring may be routed downwardly or upwardly. In apreferred aspect, each of the strands of wiring are routed from theupper compartment space downwardly into the lower compartment spacewhere the proximal end is connected to a breaker in the circuit breakerpanel casing; the distal portion of each strand of wiring is coiled tofit within the upper compartment space. In an alternative aspect, theproximal end of the wiring may be connected to a breaker first and thenthe distal portion of the wiring may be routed upwardly and coiled forstoring in the upper compartment space.

In the preferred aspect of the invention, the prefab electrical moduleis further weatherized. The top and back of the panel casing are coveredwith a waterproof membrane. The wiring comprises weatherproof and/oroutdoor wiring. The openings in the top wall of the panel casing throughwhich the wiring runs are sealed, such as by the use of waterproofputty, such as may be sold as electrical insulation putty. Further, awaterproof weatherstrip is attached between the front face of the panelcasing and the temporary panel casing front cover to provide additionalprotection from weather.

To transport the prefab electrical module to the jobsite, the front ofthe panel casing is covered by the temporary panel casing front cover,which encloses the circuit breakers in the lower compartment. The topand front of the chase and of the forwardly projecting wiring arecovered and protected by the guard cover. The guard cover has an upperhoisting handle that is attached securely enough to allow lifting of theprefab electrical module. Multiple modules may be stacked on pallets andshipped to the jobsite for distribution to the individual residential orcommercial units.

To install a prefab electrical module into the residential or commercialunit for which it has been prepared, a hoisting bracket is preferablyinstalled at the top of the stud bay into which the prefab electricalmodule will be permanently mounted. A drill-powered winch is attachedbetween the hoisting bracket and the hoisting handle to lift the moduleinto the bay and to easily position it at the proper height where it isthen fixedly attached to the stud walls.

The inventive prefab electrical module and its fabrication, transport,and installation systems and methods provide many advantages overconventional circuit breaker panel installations. Use of the prefabelectrical module eliminates the most time-consuming part of installinga unit's electrical system, which is making up the circuit breaker panelat the jobsite, which includes at least attaching the proximal end ofeach wire to the proper circuit breaker per the pre-specified electricallayout and labeling the breaker and/or wire. Using the inventive modulethat provides pre-completed circuit breaker wiring reduces labor costsin the field, which reduces the overall cost of construction, sinceon-site labor costs are higher than labor costs in the fabricationplant. It also provides uniformity and consistency of the wiring of thecircuit breaker panels of the units. Using the prefab electrical modulefor electrical installations during construction also reduces lost orwasted material, because homerun wiring of the correct type is pre-cutto the exact length needed for each circuit and is transported to thespecific unit within the prefab electrical module designated for thatunit.

A significant advantage is that the weatherproofing of the prefabelectrical module enables early installation and advances the timelinefor the rough electrical inspection. The rough electrical installationon the lower floor or floors of a multi-floor building can be completedwithout waiting for the building envelope to be dried-in. Consequently,the rough electrical inspection can be moved up in time, potentiallyshaving months of time off a construction schedule for multi-floorbuildings, with the amount of time saved increasing substantially as thenumber of units and/or floors in the building being constructedincreases. This allows projects to finish earlier and allows incomegeneration from sales or rentals to begin sooner.

Additionally, the instant invention increases quality consistency andreduces material wastage compared to making up the circuit breakermodule at the building site. Time-consuming mistakes are eliminatedbecause the making up of every circuit breaker panel is consistent. Thiscontrasts with conventional installations in which panels are made updifferently by different electricians in the field. Every inventiveprefab electrical module goes through strict quality control checks byexperienced electricians, thus delivering assurance of reliability andquality to the building owners.

Further, the prefab electrical modules provide shipping advantages. Themodules are fabricated in a consistent height, width, and depth for easytransport. Multiple inventive modules can be palletized and shipped onstandard pallets thus reducing transportation costs and enablingworldwide shipping. Prefab electrical modules for an entire floor ofapartments or for a full section of homes can be shipped from thefabrication facility at once, instead of being created one by one in thefield.

In addition, the specific configuration of the prefab electrical moduleallows installation into a wall formed by conventionally sized 2×4 studs(or, optionally, in the less common 2×6 sized wall stud bays). The chaseis attached above the panel casing carrying the circuit breakers withthe removable guard cover extending forwardly from the front of thechase. The chase and the panel casing have a depth equal to or less thanthe depth of the wall studs. The guard cover extends beyond the frontedges of the 2×4 wall, but it is only used temporarily to cover thewiring; it is removed after the homerun wiring is run. Thus, theportions of the prefab module that remain in the wall have a depth thatis accommodated by the 2×4 wall studs. This provides a significantadvantage because the prefab module is readily usable in standard 2×4walls.

Though the prefab electrical module is shown and described herein as amain service electrical panel assembly, the housings and panel casingscan also be used to fabricate, transport, and install other electricalassemblies, such as a low-voltage electrical assembly or the like.

Though this description focuses on the usage of the prefab electricalmodule, methods of fabrication, and installation of the modules foron-site construction, the invention also provides advantages forprefabrication construction at a manufacturing facility, such as at awall prefabrication factory. When the modules are installed at a factoryinto prefabricated walls, they reduce cost and waste and increaseconsistency, uniformity, and reliability.

The object of the invention is to provide a system and method forelectrical installation, particularly during initial buildingconstruction, which gives an improved performance over the prior artsystems and methods.

These and other objects, features, and advantages of the presentinvention will become more readily apparent from the attached drawingsand from the detailed description of the preferred embodiments whichfollow.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be describedin conjunction with the appended drawings, provided to illustrate andnot to limit the invention, where like designations denote likeelements.

FIG. 1 is a perspective front view of an embodiment of the prefabelectrical module of the present invention with mounted wiring andbefore installation of the guard cover and temporary panel casing frontcover for transport.

FIG. 2 is a front view of an embodiment of the prefab electrical moduleof the present invention with mounted wiring and before installation ofthe guard cover and temporary panel casing front cover for transport.

FIG. 3 is a left side view of an embodiment of the prefab electricalmodule of the present invention with mounted wiring and beforeinstallation of the guard cover and temporary panel casing front coverfor transport.

FIG. 4 is a perspective front view of an embodiment of the prefabelectrical module of the present invention with the upper guard coverand temporary panel casing front cover installed.

FIG. 5 is a left side view of an embodiment of the prefab electricalmodule of the present invention with the guard cover and temporary panelcasing front cover installed.

FIG. 6 is a perspective back view of an embodiment of the prefabelectrical module of the present invention with the guard cover,temporary panel casing front cover, and waterproof membrane installed.

FIG. 7 is a front view of an embodiment of the prefab electrical moduleof the present invention with the guard cover and temporary panel casingfront cover installed.

FIG. 8 is a back view of an embodiment of the prefab electrical moduleof the present invention with the guard cover and waterproof membraneinstalled.

FIG. 9 is a top view of a guard cover of an embodiment of the presentinvention.

FIG. 10 is a top view of a prefab electrical module of an embodiment ofthe present invention in which the guard cover is not installed and inwhich multiple strands of homerun wiring are secured to, and extendforwardly from, the chase.

FIG. 11 is a bottom view of a prefab electrical module of an embodimentof the present invention with a temporary panel casing front cover and aguard cover installed.

FIG. 12 is a perspective side view of a guard cover of the presentinvention.

FIG. 13 is a perspective rear view of a guard cover of the presentinvention.

FIG. 14 is a front view of the installation into a stud bay of a prefabelectrical module of the present invention with the guard cover andtemporary panel casing front cover installed and with the hoistingbracket, winch, and drill positioned to lift and lifting the module intoplace within the stud bay.

FIG. 15 is a front view of a prefab electrical module of the presentinvention installed within a stud bay and with the guard cover andtemporary panel casing front cover removed.

FIG. 16 is a perspective front view of a hoisting bracket of the presentinvention.

FIG. 17 is a front view of the hoisting bracket of the presentinvention.

FIG. 18 is a perspective back view of the circuit breaker panel casingof the present invention that is weatherized by the addition of awaterproof membrane.

FIG. 19 is a perspective top view of the circuit breaker panel casing ofthe present invention that is weatherized by the addition of awaterproof membrane.

FIG. 20 is a perspective rear view of the chase of the presentinvention.

FIG. 21 is a perspective view of homerun strands of wiring of thepresent invention.

FIG. 22 is a front view of a unit panel schedule utilized in thefabrication and the installation of the prefab electrical modules of thepresent invention.

FIG. 23 is a flowchart showing a method of fabrication of a prefabelectrical module of the present invention.

FIG. 24 is a flowchart showing methods of shipping the prefab electricalmodule of the present invention and of mounting it within a wall studbay at a construction site.

Like reference numerals refer to like parts throughout the several viewsof the drawings.

DETAILED DESCRIPTION OF THE INVENTION

Shown throughout the figures, the present invention is directed toward aprefabricated (“prefab”) electrical module 100 used in buildingconstruction and toward methods of fabrication 230 (FIG. 23 ) andmethods of transport and installation 240 (FIG. 24 ) of the modules 100.Usage of the modules 100 provides advantages for on-site constructionbecause it enables early (before dry-in) installation to allow the roughelectrical inspection to be moved quite significantly earlier. Thedesign of the modules 100 also minimizes the cost for shipping ortransport to the place at which the installation will occur, becausemultiple modules 100 can be palletized. The systems and methods providedtogether create a system usable in all residential and commercialconstruction, but which is particularly suitable for use in theelectrical installation of multi-family or other multi-unitconstruction.

The components of the prefab electrical module 100 that will remainpermanently within the building include a circuit breaker panel casing180, a set of circuit breakers 185, a chase 130, and the homerun wiring170. The interior of the circuit breaker panel casing 180 defines theback, top, bottom, and sides of a lower compartment space 120 thathouses the set of circuit breakers 185. The interior of the chase 130defines the back and sides of an upper compartment space no for carryingthe unit's homerun wiring 170 during transport. Each strand of wiring170 is attached to a breaker 186 in the panel casing 180 and is run intothe chase's upper compartment space no where it is coiled and storeduntil installation.

The non-permanently installed and/or reusable components of the prefabelectrical module 100 are a temporary panel casing front cover 184 (FIG.14 ) and a guard cover 190 (FIG. 4 ). The temporary panel casing frontcover 184 fits over the front face of the panel casing 180 to enclose itto provide protection during shipping and to provide weatherproofingafter installation into the stud bay but before running of the wiring170. The panel casing front cover 184 defines the front of the lowercompartment. Thus, the panel casing front cover 184 together with thecircuit breaker panel casing 180 define the lower compartment space 120.

The guard cover 190 fits over the top of the chase 130 and projectsforwardly from the front of the chase 130. The guard cover 190 definesthe top, the forward portion of the bottom, the forward portions of thesides, and the front portion of the upper compartment space 100. Thus,the guard cover 190 together with the chase 130 define the uppercompartment space no. The guard cover 190 is configured with an upperhoisting handle 195.

Other components in the prefab electrical system that are used duringmounting of the module 100 into the stud bay 210, and that are reused ininstalling multiple modules, include a hoisting bracket iso and a drillhoist 220 powered by a drill 221 (FIG. 14 ).

The circuit breaker panel casing 180 includes a top wall 121, opposingside walls 123, a back wall 125, and a bottom wall 129. A set of circuitbreakers 185 is fixedly attached within the panel casing 180.

To weatherize the panel casing 180, a waterproof membrane 160 (FIGS.18-19 ) is applied 232 (FIG. 23 ) to the outer upper surface of the topwall 121 and to the outer rear surface of the back wall 125. Thewaterproof membrane 160 may comprise any thin waterproof material,fabric, or sheeting that self-adheres or can be adhered to the outsidesurface of the panel casing 180. A membrane top portion 161 is adheredto the top surface of the panel casing top wall 121, and a back portion169 of the membrane is adhered to the outside surface of the panelcasing back 125. In a preferred aspect of the invention, the waterproofmembrane comprises a self-adhering roofing underlayment, such as soldunder the trademark of GRACE ICE & WATER SHIELD. In this aspect, theself-adhering roofing underlayment is formed of a rubberized asphaltadhesive backed by a layer of release film that protects its adhesivequality. The modified bitumen forms a watertight seal even if there isan accidental puncture of the waterproof membrane 160. The release filmis easily removed. The rubberized asphalt layer bonds tightly to theback and sides of the panel casing 180. After application of thewaterproof membrane, holes 128 defined by hole edges 127 (FIG. 19 ) maybe cut, as needed, to allow the wiring 170 to be routed between theupper compartment space no and the lower compartment space 120.

Though a waterproof membrane 160 is disposed on the top wall 121 and theback wall 125 of the panel casing 180, no waterproof membrane 160 isdisposed on the chase 130 or the guard cover 190. The panel casing 180forms a watertight compartment without the need to use extra waterproofmembrane 160 on any other portion of the module 100. This saves on thecost of materials, reduces costs for the module fabricator that can bepassed along to the unit developer, and reduces the environmental impactby reducing the amount of materials used. (The use of a waterproofingmaterial 175 around the portion of wire 170 running through hole 128aids in creating a watertight compartment.)

The chase 130, the lower portions of which are attached to the panelcasing 180, provides a rigid frame to which the guard cover 190 can beattached. The chase 130 includes a back wall 138 (FIGS. 6, 8, 20 ),opposing right and left side walls 133, and, preferably, opposing rightand left lips 132 (FIG. 2 ). The back wall 138 provides a rearprotective barrier for the wiring 170. The back wall 138 and side walls133 extend vertically between a chase top edge 131 and a chase backbottom edge 119 (FIG. 6 ). The back wall 138 extends horizontallybetween, and forms a right angle with, the side walls 133. The optionalopposing right and left lips 132 form right angles with the forwardmostedges 179 of the right and left side walls 133 and provide support forthe sides of the chase 130. The lips 132 are disposed on the upperportion of the forward-facing edges of the right and left side walls133. The right and left lips 132 extend vertically between the chase topedge 131 and a lip bottom edge 139 (FIG. 2 ). The lips 132 do not extenddownwardly the full vertical height of the side walls 133. This allowsthe lip bottom edge 139 to abut the top of the panel casing 180 when thechase 130 is installed onto the top of the panel casing 180. This is incontrast to the chase side wall 133 that extends downwardly a greaterdistance (beyond the lip 132) to overlap a top portion of the panelcasing side wall 123 for easy attachment of the chase 130 to the panelcasing 120. Therefore, the distance from the chase top edge 131 to thelip bottom edge 139 is less than the distance from the chase top edge131 to the chase back wall and side wall bottom edge 119. Preferably thelip 132 has a vertical length greater than one half of the verticallength of the side wall 133.

In a preferred aspect of the invention, the chase 130 is metal and theback wall 138, opposing right and left side walls 133, and opposingright and left lips 132 are formed integrally and unitarily. In anotheraspect of the invention the chase 130 may be formed from othermaterials, such as plastic. In a further aspect, the chase 130 may beformed of multiple components that are fixedly joined together.

The chase 130 is disposed above the top of the panel casing 180. Thechase side walls 133 extend downwardly to overlap a portion of the panelcasing side walls 123 to provide a strong connection. The chase 130 isfixedly attached 233 (FIG. 23 ) to the panel casing 180 by connectiondevices 137, such as by rivets, screws, or bolts, as shown in FIG. 1 .Preferably, the chase 130 is fabricated of metal in a metal fabricationshop with laser cutout holes 135 defined by cutout edges 136 that arelaser cut into the metal of the back wall 138. In another aspect of theinvention, the chase 130 and the panel casing 180 may be formedunitarily with cutouts 135 cut into, or molded or formed within, theback wall 138 of the chase portion of the unitarily formed component. Inthe preferred aspect of the invention, the circuit breaker panel casing180 and the chase 130 are formed separately of metal, and the chase 130has an open top, open bottom, and open front.

One or multiple spreader bars 104 are affixed 234 (FIG. 23 ) within theupper compartment space no and extend between the chase's opposing sidewalls 133, as shown in FIG. 1 . In the aspect in which the chase 130 andthe panel casing 180 are formed unitarily, the spreader bars 104 may beformed unitarily with them.

The spreader bars 104 provide an efficient means to strengthen the chase130 and provide a useful structure onto which the wiring 170 may beattached. The cutouts 135 are openings that extend through the back wall138; they provide a convenient means of attachment for wiring-to-chaseattachment devices such as zip ties 171. A zip tie 171 may be routed outone cutout 135 and into another cutout 135 and then secured around thewiring 170 to hold it in place. The rearmost coil of wiring 170 is heldagainst the inner surface of the back wall 138 with the other coils ofwiring 170 held in front of the rearmost coil. Typically (based on thelength of wiring needed for most units), the outermost coils of wiringextend outwardly beyond the outer front edges of the back wall 138 andof the opposing side walls 133 of the chase 130. Thus, the guard coverforward extension is needed to contain the entirety of the wiring 170and to accomplish sealing the wiring 170 into the module 100 to form acompact entity.

To customize the prefab electrical module 100 for the specific unit intowhich it will be installed, an electrical unit layout is engineered forthat specific unit, and a unit panel schedule 140 (FIGS. 15, 22 ) isprepared based on that predetermined, engineered layout. It will be usedboth by the prefab electricians to measure and cut wiring and to wirethe breakers of the module 100 and by the electricians at theconstruction site to install the homerun wiring 170 of the module 100.In an example, to prepare an accurate unit panel schedule 140 during theprocess of the construction of multi-unit residential or commercialbuildings, the electrical contractor supplies to the framer the desiredlocations for the main service electrical service and/or the components(switches and receptacles). Coordination meetings ensure that thelocations provided are acceptable. Once the locations have been verifiedand approval has been received, the electrical contractor prepares awritten plan including roping diagrams and boxing diagrams specifyingthe locations of all devices within the units. The electrical contractoridentifies pathways for each circuit and the length to their homerunlocations. Based on this, the electrical contractor identifies allcomponents (switches and receptacles) that will be used within theresidential or commercial unit and creates an electrical unit layout orprefab plan that uses one (or, at times, more) of the weatherized prefabelectrical modules 100. A unit panel schedule 140 and unit layout (basedon the electrical unit layout) are prepared 231 (FIG. 23 ) for eachunit. Since multiple units of the same design are typically included ina multi-unit building or in a housing development, typically the unitpanel schedules 140 and unit layouts will be applicable to multipleunits within a construction phase.

The unit panel schedule 140 lists the specifications for the wire 170needed for each circuit. The specifications may include homerun wirefootages 141, the wiring type 145, and the load/breaker name 144, unittype, type of breaker 186, and the like. Preferably each of the homerunwire footages 141 is color-coded. The unit panel schedule 140 is printedout and preferably laminated for jobsite durability. After making up thecircuit breaker panel, a printed copy of the unit panel schedule 140will be attached 261 (FIG. 23 ) (such as via a zip tie) within thecircuit breaker panel casing 180 for use by the electricians at thejobsite.

To begin to make up the circuit breaker panel for a unit, lengths ofhomerun wiring are measured and cut 235 (FIG. 23 ). Using the unit panelschedule 140 to determine the wire lengths needed for each breaker 186,the electrical wiring 170 is cut in footages that match the footageslisted on the panel schedule 140. In the preferred embodiment of theinvention, weatherproof electrical wiring, such as UF wire or outdoorwiring, is used instead of the typical non-weatherproof wire, such assold under the trademark ROMEX. The weatherproof electrical wiring hasan encasement that protects each interior wire and does not allowmoisture or other external elements to travel to the inside of thecable.

An electrician at the electric prefab facility follows the specifics ofthe unit panel schedule 140 to connect the proximal end of each wire 170to the proper breaker 186 within the circuit breaker panel casing 180.The circuit breaker panel is completely wired and labeled with stickersor other labels designating the circuit (such as labeling the circuitsfor the kitchen, bathrooms, air conditioner, bedroom, oven, etc.). Theproximal end of a section of wiring 170 is attached to the circuitbreaker 186. The remainder of the wiring 170 (beyond the attachedproximal end) is extended away from the breaker 186 and is run upwardthrough the exit holes 128 of the panel casing top wall 121. Thus, eachstrand of wiring 170 extends 236 (FIG. 23 ) from a breaker 186 through ahole 128 in the panel casing top wall 121 into the chase 130.

The lengths of wiring 170 are coiled 238 (FIG. 23 ) to form a coilhaving a width less than the width of the chase 130. In a preferredaspect of the invention, the UF wiring 170 is flat and can be coiledtightly to minimize the space needed for the coils. The coils are markedwith a colored identifying agent 172 and stored attached to the chase130. The colored identifying agent 172 may be colored tape, coloredtie(s), or the like. For conformity and ease of use, the coloredidentifying agent also coordinates with the color of the location and/orthe color designating a wiring length of the panel schedule 140.Preferably, the color of the colored identifying agent corresponds to aparticular length and corresponds to the color of the wiring length onthe panel schedule 140, to aid the electrician at the jobsite. Forexample, red colored tape is attached to the coil of wire that has beenconnected to the breaker for the dining room, and the dining room nameand/or coil length is designated with red highlighting or coloring onthe panel schedule. In a second example, red colored tape is attached toany coil of wire that has a homerun length of 50 feet, and the length of50 feet is designated with red highlighting or coloring on the panelschedule. This color labeling reduces errors in the onsite installation.

The wire 170 may be first attached to the breaker 186 and run up throughone of the holes 128 in the panel casing top wall 121 to be coiled inthe upper compartment space no, or the wire 170 may first be coiled witha portion run downward through a hole 128 and then connected to abreaker 186. Preferably a sleeve 115 (such as a plastic sleeve) isinstalled within the panel casing top wall hole 128, and the wire is runthrough a center opening in the sleeve 115. The sleeve 115 acts toprotect the wiring from abrasion caused by rubbing against the sides ofthe hole 128. The portion of wire 170 disposed at the hole 128 and thesleeve 115 is waterproofed 237 (FIG. 23 ) such as with a waterproofingmaterial 175, for example the electrical insulation putty sold under thetrademark 3M. The waterproofing material 175 is applied at the top ofthe sleeve 115 to seal the top of the center opening and applied aroundthe portion of wire exiting the opening at the top of the sleeve 115.Preferably it extends from the wiring downward to cover the sleeve 115and to end at the top of the panel casing 180, as seen in FIGS. 1-2 .The waterproofing material 175 is preferably sticky and self-adhering(such as the electrical putty), which prevents any water from enteringthe circuit breaker panel casing 180 through the holes 128 or throughthe sleeve 115 lining the hole 128.

The wiring coils are secured 239 (FIG. 23 ) with a binding device 171,such as heavy-duty zip ties, within the chase 130; this holds the wiring170 in a tidy and organized manner for shipping to the constructionsite. The zip ties 171 are run around the coils and around one or morespreader bars 104, routed out one cutout 135 in the chase back wall 138and back into the upper compartment via a second cutout 135, and thentightened. When needed to meet applicable regional regulations, the ziptie 171 connects the wiring 170 to the lower spreader bar 104, such asto meet a twelve-inch strapping code requirement. Additional supports134 may be added as needed based on such factors as the strength of thechase 130 material and the amount of wiring 170 to be carried within thechase 130.

After the proximal end of each wire 170 in the lower compartment space120 is neatly installed and landed into a breaker 186 per thedesignation of the unit panel schedule 140, the inside of the panelcasing 180 is preferably vacuumed. A laminated printed copy of a unitpanel schedule 140 is attached 261 (FIG. 23 ) inside, such as by a ziptie. A waterproof seal 122 is created between the front edge of thepanel casing 180 and a panel casing front cover 184 that willtemporarily be attached to the front of the panel casing 180 forshipping. For example, a foam waterproof gasket or weatherstrip 122 maybe installed around the face of the panel casing 180 to create thewaterproof seal. Preferably, the side of the panel casing 180 is markedwith a height-designating line 181, which can be used at the jobsite toposition the module 100 to the correct height for installation. Theprefab electrical module 100 is then sent to a quality control stationand each step is checked and inspected for quality.

When preparing the prefab electrical module 100 for shipping to thejobsite, the shipping components, a temporary chase guard cover 190 anda temporary panel casing front cover 184, are attached 262, 263 to thefronts of the chase 130 and the circuit breaker panel casing 180,respectively. Both covers remain protecting the internal components ofthe module 100 during transport to the jobsite and, after the module 100is installed in the stud bay 210, until the unit is wired with thehomerun wiring carried by the module 100.

The guard cover 190 includes a top wall 191 (FIGS. 4, 13, 14 ), opposingside walls 193, a bottom wall 199, and a front wall 194. The front wall194 extends vertically between the bottom wall 199 and the top wall 191and extends horizontally between the opposing side walls 193. Theopposing side walls 193 and the bottom wall 199 have a depth less thanthe depth of the top wall 191. When the guard cover 190 is installed,the wiring extending forwardly beyond the frontmost portions of thechase 130 is accommodated within the forward wiring-receiving portion198 of the guard cover 190 defined by the forward portion of the topwall 191, the opposing side walls 193, the bottom wall 199, and thefront wall 194. The rearward portion of the top wall 191 extends overand forms a lid for the top of the chase 130. Thus, the greater depth ofthe top wall 191 allows the top wall 191 to extend not only over theforwardly extending wiring, but also over the top of the chase 130.Preferably the guard cover 190 is affixed to the front of the chase 130by the utilization of self-tapping screws 197 (FIG. 7 ).

The top wall 191 includes a hoisting handle 195 and preferably a backlip 192. The back lip 192 extends downwardly a short distance to overlapthe top back of the chase 130 to prevent water intrusion and to providesupport.

The hoisting handle 195 is used both for hoisting the module 100 intothe stud bay 210 and for manual handling of the module 100, such as formoving the module 100 onto and off a pallet of modules 100. The hoistinghandle 195 is securely attached to the top wall 191 and extends upwardlyfrom the top wall 191. Though the hoisting handle 195 is illustrated ina handle shape, the hoisting handle 195 may take other forms, such as aloop. The housing handle 195 includes two ends 196 that are attached tothe top wall 191 and with a center segment 177 fixedly attached betweenthe opposing ends 177, such as by rivets or other robust attachmentmechanisms. The center segment 177 is elevated above the top wall 191 toallow attachment of a fastener or hook 225, for use in the installationof the module 100. In an example, the hoisting handle 195 has a firstend 196 attached to the top wall 191, a second end 196 attached to thetop wall 191 at a distance from the first end's attachment point, and ashaft 177 extending between the first and second ends 196. Though shownas fixedly and permanently attached, the hoisting handle 195 may betemporarily attached, such as by the use of bolts with nuts.

The temporary panel casing front cover 184 is a sheet of material thatis sized to cover the front opening of the circuit breaker panel casing180. Preferably the sheet of material is metal, though plastic or otherwaterproof material may be used. The panel casing front cover 184 ispreferably screwed down onto the face of the circuit breaker panelcasing 180 with multiple tamper-resistant casing self-tapping screws 187(FIG. 7 ). Tamper-resistant screws are preferred to reduce theft.Optionally, cardboard and/or plastic may be installed over all or partof the front of the module 100 to secure and protect the interiorelements during transport. Also optionally, a plastic membrane may bewrapped around all or part of the module 100 if needed, as based onshipping considerations.

Labeling of the completed module 100 identifies pertinent unit-specificinformation such as the name of the building into which the electricalmodule 100 will be installed, the name of the construction project, thename of a phase of a project, the building owner's name, the number orname of the unit, and/or other relevant unit-specific information thatis important to convey to the installing electrician. Labels or stickers188 (FIGS. 7, 14, 15 ) are preferably applied to the front surface ofthe temporary panel casing front cover 184 to indicate this pertinentunit-specific information.

In an example of a field installation at a construction site, thecompleted prefab electrical module 100 (including the components thatwill be permanently installed and the shipping components) is thentransported to the construction site on a pallet with other modules fornearby units.

In the case of multi-unit construction, multiple modules 100 that areneeded for installation into the same building or floor are alsofabricated using their own predetermined, engineered unit panel schedule140 and the unit layout as a guide. Though designed for different units,the modules are preferably a consistent width, depth, and height (forexample, all modules are preferably 4 feet in height to fit on aconventional pallet). An entire floor of modules for apartment units orfor a section of homes in a housing development can be shipped out atonce.

After completion of the modules 100, the multiple modules 100 are thenstacked 241 (FIG. 24 ) on a shipping pallet. The pallet is banded,shrink wrapped, and labeled 242 (FIG. 24 ) with data (such as by a labelsimilar to the label 188 of FIGS. 7, 14, 15 ) to identify the locationof installation (such as the complex name, section name, building name,and/or building floor). The pallet is then shipped 243 to theconstruction site. In a preferred aspect of the invention, the pallet isthen unloaded 244 and positioned on or near the corresponding floor orsection. The modules 100 are removed from the pallet, loaded onto a flatcart to be manually rolled to the door of the correct unit, and thenplaced near the stud bay 210 into which the module 100 will beinstalled. The correct unit can be identified by looking at the label188 attached to the front of the module 100.

Before installation of the prefab electrical module 100, the verticalstud at the side of the stud bay 210 is indicated 245 (FIG. 24 ) with amark 105 (FIG. 15 ) at the particular height that satisfies the localregulations in affect at the location of the unit. For example, with ageneral service electrical breaker panel, the proper mounting height maytypically be 48 inches. The mark 105 on the stud is correlated with theheight-designating line 181 of the module 100.

To install the prefab electrical module 100, installation components ofthe prefab electrical system are used. These include a reusable hoistingbracket iso and a drill hoist 220 powered by a drill 221.

The hoisting bracket 15 o, as seen in FIGS. 14 and 16-17 , is astructure that can be firmly affixed 246 within the top of the stud bay210 securely enough to allow the hoist 220 to lift the module 100 intoplace. The hoisting bracket iso includes a securely attached hoistingloop 155. This loop 155 provides a connection point for a connector 225connected to a cable 222 of the hoist 220.

In an exemplary construction shown in the figures, the hoisting bracketiso (FIGS. 14, 16-17 ) includes two vertical members 157, two horizontalmembers (upper horizontal member 151, and lower horizontal member 159),and four forwardly extending braces 158. The upper and lower horizontalmembers fit in the space between the two vertical 2×4 studs that formthe vertical members of the stud bay 210. The left and right verticalmembers are spaced to fit within the opening between the vertical 2×4studs (which are typically wooden studs but may be metal studs, as iscommon in some localities) and adjacent to the inner surface of thevertical 2×4 studs. The upper and lower ends of each of the verticalmembers 157 are connected to the upper horizontal member 151 and to thelower horizontal member 159, respectively. The hoisting loop 155 isfixedly and robustly attached to the hoisting bracket 150 and preferablyto the upper horizontal member 151.

The four braces 158 each serve as an attachment point for attaching thehoisting bracket 150 to the upper end of the stud bay 210. The two rightbraces 158 have a forwardly extending portion that extends from theupper and lower ends, respectively, of the right vertical member 157.The two left braces 158 have a forwardly extending portion that extendsfrom the upper and lower ends, respectively, of the left vertical member157. The four braces 158 have a face portion 156 extending outwardlyfrom the forward ends of the forwardly extending brace portions. Whenthe hoisting bracket 150 is installed within the bay, the face portions156 will be adjacent to the front face of the vertical studs of the studbay 210. Each brace face portion 156 has a hole that receives a screw. Ascrew is inserted into the hole of a face portion 156 and is screwedinto the wood of the front face of the vertical stud.

Though the module 100 may be lifted into the bay 210 manually, in apreferred aspect of the invention, a portable drill winch 220 andportable drill 221 are used so that the module may be elevated at thepush of a button. In a preferred embodiment, the portable handheld drillwinch 220, which has a sufficient single line pulling capacity to liftthe module 100, is powered by a standard, portable drill 221. Thehoisting connection means 222 (such as a cable, chain, or rope, whichmay be steel or synthetic) is attached 247, 248 (FIG. 24 ) by upper andlower rigging hooks 225 to the hoisting handle 195 of the guard cover190 and to the hoisting loop 155 of the hoisting bracket 150. The drill221 is then activated 249 (FIG. 24 ) to power the drill winch 220 tohoist the module 100 into the stud bay 210. The height to which themodule 100 will be lifted is determined by matching theheight-designating line 181 of the circuit breaker panel casing 180 tothe regulation height line 105 that has been marked on side of the bay210.

The module 100 is then fixedly attached within the bay 210 by attachmentdevices. In a preferred example, the temporary panel casing front cover184 is then briefly removed 250 (FIG. 24 ) to allow screws to beinserted through the panel casing side walls 123 and into the verticalstuds at the sides of the stud bay 210. This secures the module 100 inplace. The temporary panel casing front cover 184 is then screwed backonto the front of the panel casing 180. (The panel casing front cover184 will remain in place until the dwelling or office is completed.)

Even though the electrical module 100 is installed into the stud bay,the onsite electricians can remove the guard cover 190 from the front ofthe panel casing 180 to access the homerun wring 170. (If the top wall191 includes a back lip 192, the back lip 192 may be released byslightly elevating the guard cover 190 as it is removed.) Theelectricians then run 251 (FIG. 24 ) the homerun wiring 170 using theunit panel schedule 140 as a guide. The wires 170 are uncoiled, holesare drilled at the top of the stud bay 210, and the wires 170 are routedto their final locations.

After running the homerun wiring 170, the guard cover 190 that wasremoved can be returned 252 (FIG. 24 ) to the prefabrication facility tobe used with another module wo to be produced. The weatherproofelectrical putty 175 and foam gasket maintain the inside of the circuitbreaker panel casing 180 free from moisture until upper floors and/or aroof are established in the building. After dry-in, any remainingelectrical devices (such as a non-weatherized switches or receptacles)are installed.

After the dwelling or commercial building is completed and painted, thetemporary panel casing front cover 184 is removed from the front of thepanel casing 180 and may be returned to the fabrication facility forreuse or may be recycled.

Though the modules 100 shown are weatherized with the panel casing 180and the wiring 170 weatherproof and able to be installed before dry-inof a building, in another aspect of the invention, the module 100 isproduced in a non-weatherized version. In the non-weatherizedembodiment, the panel casing 180 enclosing the circuit breaker is notrequired to have weatherproof membrane installed, the putty 175 is notrequired, and the wiring 170 need not be type UF cable, but it mayinstead be non-weatherized wiring, such as sold under the trademarkROMEX. Non-weatherized modules 100 may be suitable for usage atfacilities such as a manufactured home production facility. In that usecase, pallets of premade modules 100 may be prepared based on theengineered plans for the manufactured homes to be produced.

In another embodiment of the invention, the modules 100 are prepared forinstallation into prefabricated walls being assembled at a wallprefabrication factory instead of being prepared for field installationat a construction site. For the installation in a wall fabricationfactory, the modules 100 may or may not be weatherized.

The palletized modules 100 will be shipped to the wall fabricationfactory. Each module 100 is installed within its specified bay in aprefabricated wall at the proper mounting height per the electricallayout and unit panel schedule 140. Then the wall unit is shipped to thejobsite with the module 100 installed within the prefabricated wallunit. The wall units are hoisted into their proper location. Ifweatherized panel casing 180 and wiring 170 has been provided, theonsite electricians do not need to wait for dry-in to begin to run thewiring 170. After the building unit has been dried-in, any remainingnon-weatherized devices are installed. If the module 100 isnon-weatherized, the wiring 170 may be unfurled and connected to deviceslocated in nearby bays after dry-in of the unit has been achieved. Otherfacilities may also use a prefabricated wall with a non-weatherizedmodule 100, such as a manufactured home construction facility.

Whether the modules 100 are installed directly into multi-unitconstruction or are installed at a wall fabrication facility they saveonsite construction time and costs. The standardization of the modules100 and fabrication in a module fabrication facility reduces materialwaste and increases consistency and uniformity for both the weatherizedand non-weatherized embodiments of the modules 100. Each module 100 goesthrough strict quality control checks by experienced electricians, whichprovides quality control to the building developers and owners, andwhich, thus, reduces costly mistakes.

In the preferred embodiment in which the modules 100 are weatherized,the construction timeline is advanced (compared to the conventionalmethod of making up individual circuit breaker panels one by one in thefield), which allows income generation from sales or rentals to beginearlier. Onsite electricians can begin the electrical installation weeksto months earlier, before the building has windows and a roof, due tothe waterproof nature of the module 100 and the wiring 17. This allowsthe rough electrical inspection to be performed weeks to months earlier.

The inventive modules 100 provide additional advantages. The mosttime-consuming part of installing an electrical system, making up thepanel, is done at the module fabrication facility, thus saving time atthe jobsite. Time-consuming mistakes are eliminated (such as often occurwhen different electricians make up the circuit breaker panelsdifferently). Having wiring 170 pre-measured and pre-cut to exactmeasurements and ready for the onsite electrician saves materialwastage. The disclosed standardized modules 100 can be palletized andshipped economically anywhere in the world.

Since many modifications, variations, and changes in detail can be madeto the described preferred embodiments of the invention, it is intendedthat all matters in the foregoing description and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense. Thus, the scope of the invention should be determined bythe appended claims and their legal equivalents.

What is claimed is:
 1. A prefabricated electrical system, comprising: aprefab electrical module comprising: a panel casing defining a lowercompartment space accommodating multiple circuit breakers; said panelcasing comprising a waterproof membrane affixed to a top surface and aback surface of said panel casing; said top surface; wherein said topsurface is configured with casing holes defined by casing hole edges; achase disposed above said panel casing and defining a rearward portionof an upper compartment; and a guard cover removably attachable to anddetachable from a front portion of said chase and defining a forwardportion of said upper compartment; and multiple lengths of homerunwiring, each of which comprise a coil formed of an upper portion of afirst length of homerun wiring disposed within said upper compartment, amiddle portion of said first length of homerun wiring extending throughsaid casing holes, and a lower portion of said first length of homerunwiring attached to one of said multiple circuit breakers.
 2. Theprefabricated electrical system as recited in claim 1, wherein saidwaterproof membrane comprises a rubberized asphalt.
 3. The prefabricatedelectrical system as recited in claim 1, wherein said waterproofmembrane comprises a self-adhering roofing underlayment.
 4. Theprefabricated electrical system as recited in claim 1, furthercomprising a unit circuit panel schedule for a specific unit to beconstructed that is removably attached within said lower compartmentspace and that displays electrical information for said specific unit;wherein each of said multiple lengths of homerun wiring has a lengthindicated by said unit circuit panel schedule.
 5. The prefabricatedelectrical system as recited in claim 4, further comprising a coloredidentifying agent attached to each of said multiple lengths of homerunwiring; wherein said unit circuit panel schedule comprises a colordesignating a wire length or an installation location; wherein a colorof said colored identifying agent corresponds to at least one of saidcolor designating a wire length or an installation location.
 6. Theprefabricated electrical system as recited in claim 1, wherein said eachof said multiple lengths of homerun wiring comprises weatherized UFwiring.
 7. The prefabricated electrical system as recited in claim 1,further comprising waterproofing material disposed at said casing holesto increase water resistance of said panel casing.
 8. The prefabricatedelectrical system as recited in claim 7, wherein no waterproof membraneis disposed on an exterior surface of said chase; and wherein nowaterproof membrane is disposed on an exterior surface of said guardcover.
 9. The prefabricated electrical system as recited in claim 1,wherein said coil formed of an upper portion of a first length ofhomerun wiring extends outwardly beyond rearward portion of an uppercompartment formed by said chase and, after installation of said guardcover, extends into said guard cover.
 10. The prefabricated electricalsystem as recited in claim 1, wherein said chase comprises a chase backwall configured with cutout holes defined by cutout edges disposedwithin said chase back wall to receive wiring-to-chase attachmentdevices to secure said multiple lengths of homerun wiring within saidupper compartment.
 11. The prefabricated electrical system as recited inclaim 1, wherein said prefab electrical module further comprises a panelcasing front cover that is attachable to, and removable from, a front ofsaid panel casing.
 12. The prefabricated electrical system as recited inclaim 11, wherein said panel casing front cover is, after removal,reusable with additional prefab electrical modules.
 13. Theprefabricated electrical system as recited in claim 1, wherein saidguard cover is, after removal, reusable with additional prefabelectrical modules.
 14. The prefabricated electrical system as recitedin claim 1, wherein said guard cover comprises a guard cover top walland a hoisting handle disposed on said guard cover top wall for hoistingsaid prefab electrical module.
 15. The prefabricated electrical systemas recited in claim 14, further comprising: a hoisting bracket removablyattachable within a stud bay; and a hoisting connection means to connectsaid hoisting bracket to said hoisting handle to allow saidprefabricated electrical module to be hoisted into a stud bay.